Russula supplied two new water boxes to Isdemir for its 500,000 tpy two-strand wire rod mill in Iskenderun, Hatay, Turkey. The main objective of the mechanical upgrade was to improve the metallurgical properties of the wire rod by improving the temperature homogeneity. The new water boxes replaced the existing water boxes. Russula supplied all the mechanical equipment, engineering, installation advisement, commissioning support and spare parts.
After an on-site survey, the Russula team proposed the replacement of the existing water boxes to improve the wire rod bar temperature homogeneity that would thus improve the metallurgical properties of the wire rod. Since the product mix was the same, the water boxes were sized according to the same dimensions and cooling capacity as the existing boxes. The existing valve arrangement and field instrumentation were reused along with the connections to the compressed air and water. Since Russula recently upgraded the automation for the two-strand wire rod mill, only minor adjustments were made to the existing control and HMI applications.
The water boxes were shipped to the plant in February, 2018. In March 2018, the Russula team was on-site and worked hand in hand with the Isdemir mill team to supervise the installation and began running water trials. The water boxes were installed quickly and by March 23rd, the mill began hot commissioning rolling different steel sizes. The first size rolled during the commissioning was 6.0mm diameter low carbon testing at 79 m/s the multiple zones and general operations of the two new water boxes. Next, large sizes were tested by rolling 16.0 mm cold heading at 12 m/s.
When the mill was rolling 16.0 mm cold heading, the other wire rod line used four water boxes to achieve similar results to the line running with the two new boxes. The cooling of the new water boxes was better, as less water flow was required. Not only did the homogeneity of the bar improve, but the water flow rates were reduced by more than half compared to the existing line. The water flow required to reduce the bar’s temperature to 230ºC in the other cooling line was 124 m3/h. In comparison, the line with the new water boxes only required 70 m3/h to reduce the bar’s temperature to 230 ºC.
The block became the new bottleneck. It limited the maximum speed of the mill instead of the dragging forces caused by the water boxes. While in operation, no water spilled all over the area like the water boxes of the other line.
In June 2019, Russula received final acceptance for the water boxes confirming that they met all technical and performance contractual obligations. The Isdemir team was satisfied with the installation, commisssioning, contribution and support of the Russula team. With the new water boxes, the mill is able to achieve a homogenous temperature across the wire rod bar, which enhanced the mechancial properties.
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